Self-aligning connector



1970 R. c. STEPHENSON ET AL 3,4,3

' SELF-ALIGNING CONNECTOR 73 18 '19? 2 Sheets-Sheet 1 Fig. 1,

Roger C. S'ie phenson Jack D. SHller,

INVENTOR.

4 ATTORNEY. v

United States Patent 3,488,623 SELF-ALIGNING CONNECTOR Roger C. Stephenson, Van Nuys, and Jack D. Stiller, Santa Monica, Calif., assignors to Gray & Huleguard, Santa Monica, Calif., a corporation of California Filed May 18, 1967, Ser. No. 639,551 Int. Cl. H01r 21/28 US. Cl. 339-64 7 Claims ABSTRACT OF THE DISCLOSURE The present invention relates to so-called umbilical connector assemblies for temporarily interconnecting a large number of electrical circuits on one structure with a large number of electrical circuits on another structure. The assembly includes separable connectors which are mounted on the structures so as to mate when the structures are joined together and to separate when the structures separate. At least one of the connectors includes a floating alignment that allows the connector to move on its supporting structure. As a consequence even though the two structures are misaligned the two connectors can be mated and separated without any material interference. Moreover, in the event the two structures move relative to each other while the connectors are mated, the connector assembly will not be mechanically damaged and the electrical interconnection will not be disrupted.

Background of the invention Under some circumstances a connector assembly may be utilized for temporarily interconnecting a large number of electrical circuits at one location with a large number of circuits at an another location. For example, it may be desirable to interconnect the on-board circuitry carried by vehicles such as aircraft, ships, missiles, etc. with various ground based support equipment, such as power supplies, controls, etc. as long as the vehicle remains stationary. When the vehicle moves the on-board equipment becomes self-contained and is disconnected from the support equipment. A large number of so-called umbilical connectors have been provided for such purposes. However, in order to Wilhstand the severe environments sometimes encountered by the vehicles, the connectors must be of a precision nature having closely fitting parts to insure adequate sealing, mating etc. As a consequence connectors of this type must be precisely aligned at the time they are joined together and/ or are separated from each other. When one of the connectors in the assembly is merely mounted on the end of a flexible cable there is no particular problem in maintaining the assembly properly aligned.

However, under some circumstances it is necessary for both parts of the connector assembly to be mounted on fairly large rigid structures connected to each other in a predetermined relation. For example, the connector assembly may be provided between two stages of a missile for interconnecting the circuitry in the two stages. If the two stages are always maintained precisely aligned and positioned relative to each other no particular difficulties are experienced in mating or separating the two parts of the assembly nor in maintaining the two parts properly electrically connected. However, as a practical matter it has been found that when two relatively large structures, such as the stages of a missile are joined, a certain amount of misalignment is inherent as a result of mispositioning, variations in size, thermal expansion, etc. Very frequently this is of sufficient magnitude to cause a material interference with efficient operation of the connector assembly. It has also been found very frequently vibrations occur and adjacent portions of the two structures move relative to each other over a sufiicient range to materially interfere with the electrical connections in the connector. It will thus be seen connector assemblies of the umbilical type available heretofore have not been entirely suitable for all types of operations and particularly when the separable portions of the assembly are mounted on relatively large structures which cannot be mated in precise axial alignment.

The present invention provides means for overcoming the foregoing difficulties. More particularly, the present invention provides a connector assembly especially useful on large structures which may be connected together and/ or separated. The assembly includes a floating alignment whereby all portions of the assembly will be maintained properly aligned with each other irrespective of the misalignment of the supporting structures and/ or vibratory movement therebetween.

In the single embodiment of the invention disclosed herein this is accomplished by providing a connector assembly having two separable parts such as a plug and a receptacle. The plug and the receptacle include housings which contain sets of contacts and are arranged to mate with each other whereby all of the contacts in the two sets are properly electrically interconnected. At least one of the housing is supported by a mounting means which allows the housing to float on the supporting structure whereby a predetermined amount of movement may occur between the supporting structure without interfering with the mated connectors. In addition detent means are provided which insure the connectors in the assembly being locked together and will not release during the normal amount of movement between the two structures but will reliably release when the two structures are separated from each other.

These and other features and advantages of the present invention will become readily apparent from the following detailed description of a single embodiment thereof, particularly when taken in connection with the accompanying drawings wherein like reference numerals refer to like parts and wherein;

FIGURE 1 is a fragmentary cross sectional view of a pair of structures having a connector assembly, which includes one form of the present invention mounted thereon;

FIGURE 2 is an end view of the connector assembly of FIGURE 1;

FIGURE 3 is a cross sectional view of the connector assembly taken substantially along the plane of line 3-3 in FIGURE 2;

FIGURE 4 is a cross sectional view taken at substantially right angles of FIGURE 3 and substantially along the plane of 4-4 of FIGURE 2;

FIGURE 5 is a cross sectional view, on a greatly enlarged scale, of one portion of a mounting means;

FIGURE 6 is a fragmentary cross sectional view of the connector assembly during a normal separation thereof, and

FIGURE 7 is a fragmentary cross sectional view, similar to FIGURE 6, showing the separation of the connector assembly during an abnormal separation.

Description of the preferred embodiment Referring to the drawings in more detail the present invention is particularly adapted to be embodied in a connector assembly 10 for temporarily interconnecting a large number of electrical circuits in a first location with a large number of electrical circuits in another location. For example, the connector assembly 11] may be used for interconnecting the on-board circuitry of an aircraft, ship, rocket, etc. with ground based support equipment, such as control circuits, power supplies, etc.

However, the present connector assembly has been found especially useful for joining the circuits on two large structures which may be adjacent to or connected to each other particularly when they may be separated. By way of example, the present connector assembly has been particularly useful for interconnecting the circuits in one stage 12 of a rocket with the circuits in another stage 14 of the rocket. Each of the structures includes a bulkhead 16 and 18. When the two structures are mated the two bulkheads 16 and 18 are substantially parallel to each other and separated by some predetermined distance. The assembly 10 is disposed in openings 20- and 22 through the bulkheads which are aligned with each other when the structures are mated.

It can be appreciated when two large structures, such as the stages 12 and 14 of a rocket, are mated it is extremely diflicult if not impossible for all portions of the structures to be accurately aligned with each other. For example, certain tolerances are necessary when manufacturing the structures, a certain amount of limited mispositioning and misalignment of the structures inherently occurs when they are joined. It has also been found that under some circumstances the shape and/or size of one or both structures may change as a result of changes in temperature, etc. Very frequently during operation various portions of either or both structures may be subjected to vibrations of considerable magnitude.

As a result the amount of spacing between the two bulkheads 16 and 18 and their parallelism may vary. In addition the alignment of the two openings 20 and 22 may vary. In order to prevent this interfering with the operation of the connector assembly 10 a floating alignment is provided to accommodate this movement.

The connector assembly 10 includes a first connector or plug 24 adapted to be mounted on one of the structures 12 and a second connector or receptacle 26 adapted to be mounted on another structure 14. The plug 24 is mounted on the bulkhead 16 so as to be disposed in the opening 20 whereby its front or face is exposed therethrough. The connector 26 is mounted on the other bulkhead 18 so as to be disposed in the other opening 22 whereby its front or face is exposed therethrough.

The plug 24 includes a housing 28 having a mounting flange 30 which extends across the top and bottom. This flange 30 is secured to the inside of the bulkhead 16 by any suitable means, such as bolts 32. Although the present housing 28 has a generally square or rectangular configuration it should be noted it may have any other shape, such as circular. The housing 28 includes a passage 34 which extends completely therethrough. Although this passage 34 may be of any desired configuration, in the present instance it is substantially rectangular. A partition 36 may be provided to divide the passage 34 into two separate parts. i

Each part of the passage 34 includes dielectric front inserts 38, back inserts 40, grommet seals 42 and compression plates 44. The front of the insert 38 rests on an internal flange 46 whereby it cannot come out of the passage 34. By tightening the compression plate 44 all of the members will be tightly compressed together and sealed against moisture.

A plurality of electrical contacts 46 are provided in the inserts 38 and 40. (For purposes of simplification only one is shown in FIGURE 4.) In the present instance the contacts 46 are of the so-called socket variety. The sockets 46 are accessible through openings in the face of the insert 38. A plurality of electrical conductors 48 extend from the rear of the connector through the compression plate 44 and form a bundle or harness. These conductors 48 are interconnected with the various portions of the electrical circuit contained within the structure.

A clearance pocket 50 is provided in the front of the housing 28 for receiving the various portions of the second connector 26. The pocket 50 includes an enlarged section formed "by a pair of surfaces 52 and 54 generally 4 parallel to the surface of the passage 34 and a restricted section 56. The surface 52 and passage 34 form a core 106.

The receptacle connector 26 includes a mounting plate 58 having brackets 60 which extend along the inside of the bulkhead 18. The brackets 60 may be formed so as to position the main portion of the plate 58 in substantial alignment with the bulkhead 18.

The brackets 60 are secured to the bulkhead 18 by any suitable means. In the present instance a lost motion mounting connector 62 is provided which, as best seen in FIGURE 5, includes an eyelet 64 having a passage 66 extending therethrough. A bolt 68 extends through this passage 66 and secures the ey'elet 64 to the bulkhead 18. The eyelet 64 includes a reduced diameter center section 70 and two enlarged ends 72 and 74. One end is joined to the center section by a tapered or conical surface 76 which rides on the bracket 60 on the end of the mounting plate 58.

A flat washer 78 and a conical or spring washer 80 are provided between the second enlarged end 74 of the eyelet 64 and the backside of the bracket 60. By tightening the nut, conical washer 80 will be compressed and the bracket 60 firmly clamped against bulkhead 18. However, it will be possible for the bracket 60 to move upon the bulkhead 18. First of all the mounting plate 58 can move away from the bulkhead 18 by compressing the conical washer 80. In addition the bracket 60- can move parallel to the bulkhead 18 by moving relative to the reduced center section 70. Since there are a plurality of lost motion connectors 62, four in the present instance, the mounting plate 58 can move around within the opening 22 and angularly with respect to the plane of the bulkhead 18.

A receptacle housing 82 is provided upon the mounting plate 58 for movement therewith. The receptacle housing 82 has the same general rectangular configuration as the plug housing 24 and it includes a rectangular passage 84 which extends axially therethrough. This passage 84 has the same dimensions as the passage 34 in the plug housing 28 and it is divided into two separate portions by a partition 85.

Front inserts 86, rear inserts 88, grommet seals and a compression plate 92 are provided in both portions of the passage. A plurality of spring biased screws 94 are provided for forcing the compression plate 92 against the seal 90 whereby the inserts 86 and 88 are clamped in position against the flange 96. A plurality of contacts 98 are provided in the inserts 86 and 88 for mating with the contacts 46 in the first set. These contacts 98 have a pin 100 which project beyond the front insert so as to extend into the inserts 38 and sockets 46. In addition an interface seal 102 may be provided on the front insert 86 for being compressed between the front inserts 38 and 86. In the event the seal 86 is compressed excessively the inserts 86 and 88 can move back against the spring screws 94 and reduce the pressure to an adequate level for sealing.

The housing 82 includes an extension 104 on the front end thereof. The portion of the passage 84 within the extension 104 is enlarged whereby the extension 104 can fit into clearance pocket 50 and slide along the surface 52 of the core 106. In order to insure a smooth and easy mating of the extension 104 upon the core 106, guide means 108 are provided for aligning the receptacle housing 82 with the plug housing 28. By way of example the inner end of the extension 104 is beveled or tapered. Thus, during mating, the receptacle housing 82 and the mounting plate 58 will be moved into alignment. In addition guide means of the type disclosed and claimed in co-pending application Ser. No. 385,108 may be employed.

Such a guide means includes a rounded off nose or end surface 110 and a recessed clearance space 112. When the extension 104 initially engages the core 106 of the plug housing 28 it will be forced into substantially axial alignment. However, if there is initially some misalignment the end of the extension 104 can pass through the clearance space 112 formed by the recess. The rounded end surface 110 cannot bind or jamb in the enlarged portion of passage 84 even though the extension 104 is substantially out of alignment with the core 106. After the end of the extension 104 has passed over the clearance recess 112 a sufficient amount of the extension is disposed on the core 106 to insure axial alignment and prevent any binding regardless of any initial misalignment.

The pins 100 in the receptacle 26 are so positioned that they will not mate with the socket contacts 46 until after the end of the extension 104 has passed over the clearance space 112 whereby the plug 24 and receptacle 26 are aligned. This will insure a proper and precise mating of the pins and sockets.

The receptacle housing 82 may be mounted on the mounting plate 58 by any suitable means. However, in the present instance a plurality of retainer pins 114 are mounted on the flange 116 and retained in position by means of override springs 118. The pins 114 include enlarged heads that are effective to engage the mounting plate 58. Normally the receptacle housing 82 is free to slide through the mounting plate 58. However, when the two structures are brought too close together and the receptacle housing is forced backwardly through the plate, the enlarged ends of the pins 118 engage the plate 58 and the housing 82 rides against the override springs 118. As the springs 118 are compressed they absorb the over travel without imposing any undue forces upon either of the housings 28 or 84 or any other portions of the connector assembly 10.

When the two structures are joined it is desirable for the mated connectors 24 and 26 to be firmly locked together by means of a latch mechanism 120. As can be seen in FIGURE 1 there is very little clearance space between the two bulkheads 16 and 18 and the connector assembly is relatively inaccessible from the outside. Accordingly, the latch mechanism 120 must be self operating both as to its locking and unlocking.

In the present instance the latch mechanism includes a collet 122 which fits into the restricted section 56 at the bottom of the pocket 50 in the plug housing. This collet 122 is firmly secured in position by means of one or more spring biased detents 124. Normally the collet 122 is retained in this position. However, in the event of any unusually large forces the collet 122 can be torn loose from the spring detents 124 and removed from its position.

The collet 122 includes one or more resilient spring fingers 126 which are effective to extend over the outside of the extension 104. The ends of the fingers 126 include enlargements 128 adapted to drop into an annular channel 130 on the outside of the extension 12 when the receptacle housing 82 is in the fully mated position and the electrical contacts 46 and 98 are fully joined. The ends of the fingers and the extension 104 may be chamfered or beveled whereby the fingers 126 will spread apart when the extension 104 is traveling along the core 106.

A release sleeve 132 is slideably disposed on the outside of the extension 104. A plurality of springs 134 are provided between the radial flange 116 and the sleeve 132 so as to bias the release sleeve 132 toward the extended or locked position. When the sleeve 132 is in the extended or locked position it will fit over the enlargements 128 on the ends of the spring fingers 126 and maintain them compressed into the channel 130. Thus, as long as the release sleeve 134 is fully extended the housing 82 will be locked to the collet 122.

When the two connectors 24 and 28 are being mated and the fingers 126 are moving inwardly along the outside of the extension 104 they will engage the end of the release sleeve 132 and force it back on the housing 82 until such time as the ends of the fingers drop into the channel 130.

A plurality of release shafts 136 are slideably disposed in the radial flange 116 and the mounting plate 58. The

ends of the shafts 136 are secured to the released sleeve 132. A pair of spaced enlargements 138 and 140 are provided on the opposite sides of the mounting plate 58. This limits the outward travel of the sleeve 132 to the lock position. It also allows the receptacle housing 82 to move a predetermined distance relative to the mounting plate 58 without effecting the position of the release shaft 136. However, if the mounting plate 58 retreats a suflicient distance it will engage the enlarged end of the shaft 136 whereby the release sleeve 132 will commence moving with the plate 58. The sleeve 132 .is then withdrawn from the locked position and the fingers 126 are released from the channel whereby the receptacle can separate from the plug.

In order to utilize the present connector assembly the two structures 12 and 14 are brought together in a generally axially direction, i.e. the two bulkheads 16 and 18 are parallel. The initial engagement between the plug 24 and receptacle 26 occurs when the beveled end of the extension 104 contacts the rounded end 110 of the plug housing 28. As the extension 104 rides over the rounded end 110 and is guided onto the surface the receptacle housing 82 is brought into axial alignment with the plug housing 28. During this aligning phase the housing 82 may move on the mounting plate 58 and/ or the mounting plate 58 may move on the bulkhead 18. By the time the end of the extension 104 has traveled beyond the clearance recess 112 and begins sliding on the outer surface 52 of the core 106, the two housings 28 and 82 and the contacts 46 and 98 are precisely aligned. Accordingly the electrical contacts can come into complete engagement without any damage from binding, bending etc.

At some point in the mating operation the beveled end of the extension 104 will engage the beveled ends of the fingers 126 and force them outwardly whereby they ride along the extension 104. The ends of the fingers 126 then engage the release sleeve 132 and force it back against its springs 134 until the enlargements 128 drop into the channel 130. The release sleeve 132 will then travel over the fingers 126 and lock the receptacle 26 to the plug 24. In the event the two structures 12 and 14 continue to advance together after the connectors are fully mated any over travel of the connectors is accommodated by the override springs 118 between the flange 116 and the mounting plate 58. Also, if the seal 102 is too highly compressed the inserts and grommet seal are all shifted back against the spring screws 94.

Once the connectors are fully locked together the electrical contacts 46 and 98 are maintained fully and uniformly mated whereby there are no discontinuities in any of the electrical circuits. In the event any further movement occur between the two bulkheads 16 and 18, for example as a result of thermal expansions, shifting of the structures and/or vibrations, the relative movement will be accommodated by the mounting plate 58 shifting. on the bulkhead 18 and/ or the flange 116 moving against the override springs, and/or the receptacle housing 82 working back and forth through the opening in the plate 58.

When the two structures are separated they move axially away from each other. During the initial phase of the separation the receptacle housing 82 remains locked to the plug housing 28. The mounting plate 58 retreats along the housing 82 and the release shafts 136. After the separation has progressed beyond the initial stage, i.e. in excess of any normal mated movement, the plate 58 engages the enlarged heads of the released shaft 136. Further travel causes the release shafts 136 to move with the mounting plate 58 and the release sleeve 132 is withdrawn from around the fingers 126. Eventually the sleeve 132 comes into engagement with the flange 116. At this point the receptacle housing 82 is released from the plug housing 28 substantially as shown in FIGURE 6. Accordingly it will be carried with structure 14.

If for any reason the foregoing sequence of events does not occur and the release sleeve 132 is not removed from the fingers 126, the plug housing 82 remains locked to the plug housing 28. Continued separation causes a substantial force to be imposed on the collet 122. Eventually this causes the collet 122 to overcome the force of the spring detents 124 whereby the collet 122 will be carried free of the plug housing 28 substantially as shown in FIGURE 7.

While only a single embodiment of the present invention has been disclosed and described herein, it will be readily apparent to persons skilled in the art that numerous changes and modifications may be made thereto. For example, the arrangement of the various lost motion connections and the manner in which they function may be modified to fit any particular application. Also, the various latching mechanisms and their function may be modified to satisfy the requirements of any particular installation. Accordingly the foregoing drawings and description thereof are for illustrative purposes only and do not in any way limit the scope of the invention.

We claim:

1. A connector adapted to be mounted on a first structure for mating with a second connector on a second structure said connector including the combination of:

a mounting member,

fastening means for securing said member on said first structure, said fastening means being effective to allow said mounting member to move with respect to the first structure,

a housing adapted to mate with the second connector,

means securing said housing on said mounting member whereby said housing is free to move relative to said mounting member whereby said housing may remain mated with the second connector even though the first and second structures move relative to each other, and

a set of electrical contacts in the housing adapted to mate with a set of complimentary contacts in the second connector.

2. The connector of claim 1 wherein:

the contacts in one of said sets are pins and the contacts in the other set are sockets whereby said contacts must be joined and separated by traveling in straight lines parallel to the axis of the connectors, and

guide means on said housing effective to mate with the second connector and move the housing and mounting member into alignment with the second connector whereby the housing is free to travel only in a straight line before the contacts in said sets join.

3. The connector of claim 1 including:

latch means on said housing for engaging complimen tary latch means on said second connector, said latch means being effective to engage and become locked together when forced together whereby said housing is secured to said second connector when said connectors are mated,

first lost motion means effective to allow said structures to move toward each other after said housing is mated with the first connector and said latch means are locked together,

second lost motion means disposed between said housing and the latch means thereon, said second lost motion means being effective to allow said structures to separate a predetermined distance without effecting said latch means, said second lost motion means being effective to actuate and release said latch means when the structures separate beyond said predeter mined distance whereby said housing is released from the first connector.

4. The connector of claim 1 including:

a recess on said housing, said recess being adapted to receive a plurality of spring fingers when said connector mates with the first connector,

a keeper on said housing moveable between a first position effective to fit over said fingers and retain them in said recess and a second position wherein said fingers are released from said recess,

lost motion means coupled between said keeper and said housing, said lost motion means being effective to allow said keeper to normally remain in said first position while said structures are within a predetermined distance of each other, said lost motion means being effective to move said keeper into the second position when said structures separate beyond said predetermined distance.

5. The connector of claim 4 wherein:

the contacts in one of said sets are pins and the contacts in the other set are sockets whereby said contacts must be joined and separated by traveling in straight lines parallel to the axis of the connectors,

guide means on said housing effective to engage coacting guide means on the second connector when said connectors are mating, said guide means being effective to move said housing relative to said first structure to align said housing with the second connector before the contacts in said sets join whereby the housing can only travel in a straight line when said contacts are being joined and separated.

6. An electrical connector assembly for use on a pair of juxtaposed structures, said assembly including the combination of:

a plug,

mounting means for securing said plug to one of said structures,

a set of electrical contacts in said plug,

a receptacle for mating with said plug,

first guide means on said receptacle and second guide means on said plug,

mounting means for securing said receptacle to the other of said structures,

a second set of electrical contacts in said receptacle, the contacts in said second set being effective to mate with the contacts in said first set when said plug and said receptacle are mated,

said guide means and said contacts being positioned so that the extensions extend across said clearance space when the contacts in said sets are separated,

latch means effective to lock said plug and receptacles together when they are mated, and

lost motion means, coupled to said latch means, said lost motion means being effective to allow said structures to move a predetermined distance without releasing said latch means, said lost motion means being effective to release said latch means whenever said structures move more than a predetermined distance relative to each other.

7. An electrical connector assembly including the combination of:

a first connector for being mounted on a first structure,

a first set of electrical contacts in said first connector,

and a guide means,

a second connector for being mounted on a second structure,

a second set of electrical contacts in said second connector for electrically engaging the contacts in the first set, the contacts in one of said sets comprising sockets and the other said sets comprising pins which 'must be joined with and separated from the sockets by traveling in a straight line parallel to the axis of the connectors,

mounting means for mounting said second connector to the second structure whereby said second connector is free to move relative to the second structure, said mounting means including a mounting member, means for securing said mounting member in a first structure, said means being effective to allow the mounting member to move relative to the structure in a plane parallel thereto and to move oblique to said plane, and means for securing said second cona second position to release said fingers, and lost monector on said mounting means for moving normal tion means on said connector coupled to said keeper to the plane, to allow said connector to move on said mounting guide means in said second connector for co-acting means without moving said keeper into the second with the first guide means on the first connector 5 position.

when the first and second connectors are being mated, References Cited said mounting means enabling the second connector UNITED STATES PATENTS to move on said second structure when said guide means is aligning the second connector with the first 2,239,541 7/ 1942 Masmey et 24820 connector, and said guide means moving said second 10 2,371,457 1/ 1959 Je I1Ck$ 6t 33975 means on the mounting means to align the pins in 3,094,364 6/1963 Llngg 33964 the first set with the sockets of the second set and 3,152,850 10/1954 Nava et insuring the second connector traveling only in a FOREIGN PATENTS straight line before the contacts in said set 101D, and

latch means on said connector for securing said con- 15 184354 8/1922 Great Bntamnector together, said latch means including a recess i of one of said connectors, a plurality of spring fingers RICHARD MOORE Pnmary Exammer effective to fit into said recess for securing said con- RICHARD H. MCGLYNN, Assistant Examiner nectors together, a keeper on the other of said connectors movable between a first position effective to 20 3 C X- fit over said fingers and retain them in a recess and 339-91, 132 

